WO2022200604A1 - Friction stir welding tool insert - Google Patents

Friction stir welding tool insert Download PDF

Info

Publication number
WO2022200604A1
WO2022200604A1 PCT/EP2022/057995 EP2022057995W WO2022200604A1 WO 2022200604 A1 WO2022200604 A1 WO 2022200604A1 EP 2022057995 W EP2022057995 W EP 2022057995W WO 2022200604 A1 WO2022200604 A1 WO 2022200604A1
Authority
WO
WIPO (PCT)
Prior art keywords
tool insert
depth
shoulder surface
spiral
tool
Prior art date
Application number
PCT/EP2022/057995
Other languages
French (fr)
Inventor
Santonu GHOSH
Stig Åke ANDERSIN
Original Assignee
Element Six (Uk) Limited
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Element Six (Uk) Limited filed Critical Element Six (Uk) Limited
Publication of WO2022200604A1 publication Critical patent/WO2022200604A1/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/12—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding
    • B23K20/122—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding using a non-consumable tool, e.g. friction stir welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/12—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding
    • B23K20/122—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding using a non-consumable tool, e.g. friction stir welding
    • B23K20/1245—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding using a non-consumable tool, e.g. friction stir welding characterised by the apparatus
    • B23K20/1255—Tools therefor, e.g. characterised by the shape of the probe
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/02—Iron or ferrous alloys
    • B23K2103/04—Steel or steel alloys

Definitions

  • This disclosure relates to a friction stir welding (FSW) tool insert.
  • FSW friction stir welding
  • FSW tool insert for friction stir welding high temperature ferrous alloys and other high temperature alloys.
  • FSW tool assembly in which the tool insert comprises polycrystalline cubic boron nitride (PCBN).
  • FSW is a technique whereby a rotating tool is brought into forcible contact with two adjacent workpieces to be joined and the rotation of the tool creates frictional and viscous heating of the workpieces. Extensive deformation as mixing occurs along a plastic zone. Upon cooling of the plastic zone, the workpieces are joined along a welding joint. Since the workpiece remains in the solid phase, this process is technically a forging process rather than a welding process, none the less by convention, it is referred to as welding or friction stir welding and that convention is followed here.
  • the whole tool/tool holder can be a single piece of shaped tool steel, in which case it is often referred to as a ‘probe’ .
  • the tool is often in two or more parts, with an end element that is in direct contact with the material being welded, often referred to as a ‘puck’ or ‘tool insert’, and the remainder of the tool being the ‘tool holder’ which holds the puck securely and which fits into the FSW machine, so that the tool puck and tool holder together make up the ‘tool’ or ‘tool assembly’.
  • the tool puck is typically shaped to form a shoulder and a stirring pin, often with a reverse spiral cut into the surface so that during rotation it pulls metal towards the pin and pushes this down into the hole being formed by the pin.
  • FSW operations comprise a number of steps, for example: a) an insertion step (also known as the plunge step), from the point when the tool comes into contact with the workpieces to the point where the pin is fully embedded up to the shoulder in the heated and softened workpieces, b) a tool traverse, when the tool moves laterally along the line in between the workpieces to be joined, and c) an extraction step, when the tool is lifted or traversed out of the workpieces.
  • an insertion step also known as the plunge step
  • a tool traverse when the tool moves laterally along the line in between the workpieces to be joined
  • an extraction step when the tool is lifted or traversed out of the workpieces.
  • the tool traverse which is the stage primarily forming the weld, is usually performed under constant conditions; typically these conditions are rotational speed, conditions of the plunge, speed of traverse etc.
  • FSW tool inserts must be capable of withstanding high axial forces required as part of the FSW process.
  • a friction stir welding tool insert comprising polycrystalline cubic boron nitride and having a longitudinal axis of rotation about which it rotates during use, the tool insert further comprising a stirring pin and a coaxial shoulder region, wherein the shoulder region comprises a shoulder surface for engaging with the workpiece during use, the shoulder surface comprising a spiral or concentric grooves with a depth, D, wherein the depth, D, varies with the radial distance between the stirring pin and a peripheral edge of the shoulder surface.
  • Figure l is a perspective view of a tool insert in accordance with the invention.
  • Figure 2 is a side view of the tool insert of Figure 1;
  • Figure 3 is a plan view of the tool insert of Figure 1;
  • Figure 4 is cross-sectional view through the line Z-Z from Figure 3; and Figure 5 is an enlarged view of the encircled detail from Figure 3.
  • a tool insert in accordance with the invention is indicated generally at 10.
  • the tool insert 10 has a longitudinal axis of rotation 12 about which it rotates during use in the friction stir welding process. Note that this axis of rotation is not an axis of rotational symmetry due to an asymmetric thread pattern machined into the tool insert 10.
  • the tool insert 10 comprises a stirring pin 14, a shoulder region 16 and a body portion 18, all in axial alignment with each other, with the shoulder region 16 being axially intermediate the stirring pin 14 and the body portion 18.
  • the stirring pin 14, shoulder region 16 and body portion 18 are all integrally formed with each other such that the tool insert 10 is one-piece.
  • the tool insert 10 is machined out of a single PCBN block after the block has been sintered in a HPHT press.
  • the shoulder region 16 extends axially and merges into the body portion 18, which is adapted to couple with a tool holder that is connectable with a FSW machine.
  • the stirring pin 14 has a conical profile, tapering outwardly from rounded apex 20 towards circular base 22.
  • the stirring pin 14 comprises an inscribed spiral 24 running from the apex 20 downwards towards the shoulder region 16.
  • the spiral 24 has an arcuate working surface 26. Notably, there is no (vertical) overhang on the spiral 24 to facilitate laser shaping from the direction of the apex 20.
  • the shoulder region 16 comprises a shoulder surface 28 that extends from the stirring pin base 22.
  • the shoulder surface 28 extends generally perpendicularly to the longitudinal axis of rotation 12.
  • the shoulder surface 28 comprises a spiral 30 (also known as ‘scroll’) for engaging with the workpiece during FSW.
  • the spiral 30 is essential to the invention.
  • the benefit of the spiral 30 is that it balances the wear of the shoulder region 16 across the shoulder surface 28. In other words, the wear experienced by the tool insert 10 during FSW is more evenly distributed across the shoulder region 16 thanks to the special configuration of spiral 30.
  • the spiral 30 has a depth, D, that varies radially outwards from the core of the tool insert 10 towards a peripheral edge 32 of the shoulder region 16.
  • the shoulder surface 28 is planar, and it extends at an obtuse angle with respect to the longitudinal axis of rotation 12. Preferably, this angle is between 92 and 100 degrees from the vertical.
  • the depth, D is measured perpendicularly to the shoulder surface 28.
  • the depth, D gradually decreases with the distance away from the stirring pin 14. This configuration is beneficial because the greatest amount of wear is experienced closest the stirring pin 14; the lowest amount of wear is radially further out.
  • the depth is around 0.5 mm.
  • the location of which is indicated generally at Y which is remote from the stirring pin 14 the depth is around 0.2 mm. The depth changes gradually between the locations of the maximum and minimum depths.
  • the depth, D gradually increases with the distance away from the stirring pin 14.
  • the inventors have found that with this configuration, the tool produces longer lengths of good quality weld since the tool life is enhanced.
  • the depth is around 0.5 mm.
  • the spiral 30 is an arithmetic type of spiral, although other types are envisaged within the scope of the invention.
  • the spiral may have a logarithmic profile in plan view.
  • the shoulder surface is generally planar, and it extends perpendicularly to the longitudinal axis of rotation 12.
  • the depth, D, of the spiral 30 is measured in a plane that is parallel with the longitudinal axis of rotation 12.
  • grooves provided as concentric rings are used in place of the spiral 30.
  • the depth changes incrementally from ring to ring, from the maximum point to the minimum point.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Pressure Welding/Diffusion-Bonding (AREA)

Abstract

This disclosure relates to a friction stir welding tool insert comprising polycrystalline cubic boron nitride. The tool insert comprises a stirring pin and a coaxial shoulder region, wherein the shoulder region comprises a shoulder surface for engaging with the workpiece during use. The shoulder surface comprises a spiral or set of concentric grooves with a depth, D, wherein the depth, D, varies with the radial distance between the stirring pin and a peripheral edge of the shoulder surface.

Description

FRICTION STIR WELDING TOOL INSERT
FIELD OF THE INVENTION
This disclosure relates to a friction stir welding (FSW) tool insert. In particular, it relates to a FSW tool insert for friction stir welding high temperature ferrous alloys and other high temperature alloys. More particularly, it relates to a FSW tool assembly in which the tool insert comprises polycrystalline cubic boron nitride (PCBN).
BACKGROUND
FSW is a technique whereby a rotating tool is brought into forcible contact with two adjacent workpieces to be joined and the rotation of the tool creates frictional and viscous heating of the workpieces. Extensive deformation as mixing occurs along a plastic zone. Upon cooling of the plastic zone, the workpieces are joined along a welding joint. Since the workpiece remains in the solid phase, this process is technically a forging process rather than a welding process, none the less by convention, it is referred to as welding or friction stir welding and that convention is followed here.
In the case of FSW in low temperature metals, the whole tool/tool holder can be a single piece of shaped tool steel, in which case it is often referred to as a ‘probe’ . In the case here where the tool is for welding higher temperature alloys such as steel, the tool is often in two or more parts, with an end element that is in direct contact with the material being welded, often referred to as a ‘puck’ or ‘tool insert’, and the remainder of the tool being the ‘tool holder’ which holds the puck securely and which fits into the FSW machine, so that the tool puck and tool holder together make up the ‘tool’ or ‘tool assembly’. The tool puck is typically shaped to form a shoulder and a stirring pin, often with a reverse spiral cut into the surface so that during rotation it pulls metal towards the pin and pushes this down into the hole being formed by the pin.
In general, FSW operations comprise a number of steps, for example: a) an insertion step (also known as the plunge step), from the point when the tool comes into contact with the workpieces to the point where the pin is fully embedded up to the shoulder in the heated and softened workpieces, b) a tool traverse, when the tool moves laterally along the line in between the workpieces to be joined, and c) an extraction step, when the tool is lifted or traversed out of the workpieces.
The tool traverse, which is the stage primarily forming the weld, is usually performed under constant conditions; typically these conditions are rotational speed, conditions of the plunge, speed of traverse etc.
FSW tool inserts must be capable of withstanding high axial forces required as part of the FSW process. There are many tool insert geometries available. However, they do not automatically transfer to materials such as PCBN without issue. It has been demonstrated that PCBN based tool inserts are capable of withstanding the harsh FSW operating environment, where temperatures reach in excess of 1000°C. Also, tool pucks made from PCBN are relatively cost effective and highly durable. Unfortunately, the inventors have found that PCBN tool inserts wear at different rates across the shoulder. This reduces tool life and introduces inconsistency, thereby rendering such tools obsolete for welding steel or superalloys.
It is therefore an aim of the invention to provide a PCBN based tool insert that addresses the above-mentioned problem.
SUMMARY OF THE INVENTION
In accordance with the invention, there is provided a friction stir welding tool insert comprising polycrystalline cubic boron nitride and having a longitudinal axis of rotation about which it rotates during use, the tool insert further comprising a stirring pin and a coaxial shoulder region, wherein the shoulder region comprises a shoulder surface for engaging with the workpiece during use, the shoulder surface comprising a spiral or concentric grooves with a depth, D, wherein the depth, D, varies with the radial distance between the stirring pin and a peripheral edge of the shoulder surface.
Optional and/or preferable features of the invention are provided in claims 2 to 13. BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be more particularly described, by way of example only, with reference to the accompanying drawings, in which:
Figure l is a perspective view of a tool insert in accordance with the invention;
Figure 2 is a side view of the tool insert of Figure 1;
Figure 3 is a plan view of the tool insert of Figure 1;
Figure 4 is cross-sectional view through the line Z-Z from Figure 3; and Figure 5 is an enlarged view of the encircled detail from Figure 3.
The Figures are not drawn to scale.
Throughout the description, similar parts have been assigned the same reference numerals, and a detailed description is omitted for brevity.
DETAILED DESCTIPION
Referring to the Figures, a tool insert in accordance with the invention is indicated generally at 10. The tool insert 10 has a longitudinal axis of rotation 12 about which it rotates during use in the friction stir welding process. Note that this axis of rotation is not an axis of rotational symmetry due to an asymmetric thread pattern machined into the tool insert 10.
The tool insert 10 comprises a stirring pin 14, a shoulder region 16 and a body portion 18, all in axial alignment with each other, with the shoulder region 16 being axially intermediate the stirring pin 14 and the body portion 18. The stirring pin 14, shoulder region 16 and body portion 18 are all integrally formed with each other such that the tool insert 10 is one-piece. The tool insert 10 is machined out of a single PCBN block after the block has been sintered in a HPHT press. The shoulder region 16 extends axially and merges into the body portion 18, which is adapted to couple with a tool holder that is connectable with a FSW machine. The stirring pin 14 has a conical profile, tapering outwardly from rounded apex 20 towards circular base 22. The stirring pin 14 comprises an inscribed spiral 24 running from the apex 20 downwards towards the shoulder region 16. The spiral 24 has an arcuate working surface 26. Notably, there is no (vertical) overhang on the spiral 24 to facilitate laser shaping from the direction of the apex 20.
The shoulder region 16 comprises a shoulder surface 28 that extends from the stirring pin base 22. The shoulder surface 28 extends generally perpendicularly to the longitudinal axis of rotation 12. The shoulder surface 28 comprises a spiral 30 (also known as ‘scroll’) for engaging with the workpiece during FSW.
The spiral 30 is essential to the invention. The benefit of the spiral 30 is that it balances the wear of the shoulder region 16 across the shoulder surface 28. In other words, the wear experienced by the tool insert 10 during FSW is more evenly distributed across the shoulder region 16 thanks to the special configuration of spiral 30.
The spiral 30 has a depth, D, that varies radially outwards from the core of the tool insert 10 towards a peripheral edge 32 of the shoulder region 16. In this embodiment, the shoulder surface 28 is planar, and it extends at an obtuse angle with respect to the longitudinal axis of rotation 12. Preferably, this angle is between 92 and 100 degrees from the vertical. In such an embodiment, the depth, D is measured perpendicularly to the shoulder surface 28. The depth, D, gradually decreases with the distance away from the stirring pin 14. This configuration is beneficial because the greatest amount of wear is experienced closest the stirring pin 14; the lowest amount of wear is radially further out. At a maximum, the location of which is indicated generally at X which is proximate the stirring pin 14, the depth is around 0.5 mm. At a minimum, the location of which is indicated generally at Y which is remote from the stirring pin 14, the depth is around 0.2 mm. The depth changes gradually between the locations of the maximum and minimum depths.
In another embodiment (not shown), the depth, D, gradually increases with the distance away from the stirring pin 14. During initial trials, the inventors have found that with this configuration, the tool produces longer lengths of good quality weld since the tool life is enhanced. At a maximum depth, the location of which would be generally at Y in Figure 5 and remote from the stirring pin 14, the depth is around 0.5 mm. At a minimum, the location of which is indicated generally at X which is proximate to the stirring pin 14, the depth is around 0.2 mm.
As shown in Figure 3, the spiral 30 is an arithmetic type of spiral, although other types are envisaged within the scope of the invention. For example, the spiral may have a logarithmic profile in plan view.
In another embodiment, the shoulder surface is generally planar, and it extends perpendicularly to the longitudinal axis of rotation 12. In such an embodiment, the depth, D, of the spiral 30 is measured in a plane that is parallel with the longitudinal axis of rotation 12.
In another embodiment (not shown), grooves provided as concentric rings are used in place of the spiral 30. In such an embodiment, the depth changes incrementally from ring to ring, from the maximum point to the minimum point.
While this invention has been particularly shown and described with reference to embodiments, it will be understood by those skilled in the art that various changes in form and detail may be made without departing from the scope of the invention as defined by the appended claims.

Claims

1. A friction stir welding tool insert comprising polycrystalline cubic boron nitride and having a longitudinal axis of rotation about which it rotates during use, the tool insert further comprising a stirring pin and a coaxial shoulder region, wherein the shoulder region comprises a shoulder surface for engaging with the workpiece during use, the shoulder surface comprising a spiral or concentric grooves with a depth, D, wherein the depth, D, varies with the radial distance between the stirring pin and a peripheral edge of the shoulder surface.
2. The tool insert as claimed in claim 1, wherein the shoulder surface is generally planar.
3. The tool insert as claimed in claim 2, wherein the shoulder surface extends radially perpendicularly to the longitudinal axis of rotation.
4. The tool insert as claimed in claim 2, wherein the shoulder surface extends radially at an obtuse angle with respect to the longitudinal axis of rotation.
5. The tool insert as claimed in any preceding claim, wherein the depth, D, decreases towards the peripheral edge of the shoulder surface.
6. The tool insert as claimed in any of claims 1 to 4, wherein the depth, D, increases towards the peripheral edge of the shoulder surface.
7. The tool insert as claimed in any preceding claim, wherein the depth, D, varies between 0.2 and 0.5 mm.
8. The tool insert as claimed in any preceding claim, wherein the spiral or groove is a recess with an arcuate lateral cross-section.
9. The tool insert as claimed in any preceding claim, wherein the depth, D, changes gradually.
10. The tool insert as claimed in any preceding claim, wherein the spiral is an arithmetic spiral as viewed from above.
11. The tool insert as claimed in any of claims 1 to 10, wherein the spiral is a nautilus spiral as viewed from above.
12. The tool insert as claimed in any of claims 1 to 8, comprising a plurality of concentric annular grooves.
13. The tool insert as claimed in claim 12, wherein the depth changes incrementally with adjacent grooves.
PCT/EP2022/057995 2021-03-26 2022-03-25 Friction stir welding tool insert WO2022200604A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB2104264.3 2021-03-26
GBGB2104264.3A GB202104264D0 (en) 2021-03-26 2021-03-26 Friction stir welding tool insert

Publications (1)

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WO2022200604A1 true WO2022200604A1 (en) 2022-09-29

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Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2007301579A (en) * 2006-05-09 2007-11-22 Osaka Industrial Promotion Organization Friction stirring and working tool, and manufacturing method of friction stirred and worked product using the same
US8016179B2 (en) * 2006-07-17 2011-09-13 Wichita State University Friction stir welding tool having a scroll-free concentric region
JP2017070994A (en) * 2015-10-09 2017-04-13 株式会社Uacj Tool for friction stir welding and friction stir welding method

Family Cites Families (5)

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Publication number Priority date Publication date Assignee Title
JP3409791B2 (en) * 2001-01-31 2003-05-26 日本軽金属株式会社 Friction stir tool and method of using the same
US7401723B2 (en) * 2004-08-30 2008-07-22 Alcoa Inc. Advanced friction stir welding tools
WO2006138254A2 (en) * 2005-06-10 2006-12-28 Sii Megadiamond, Inc. Friction stirring of high softening temperature materials using new surface features on a tool
CN101774081B (en) * 2010-03-09 2012-02-01 南京航空航天大学 Weld seam lowering and thickness thinning combined stirrer used for friction stir welding
GB202013686D0 (en) * 2020-09-01 2020-10-14 Element Six Uk Ltd Friction stir welding tool insert

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2007301579A (en) * 2006-05-09 2007-11-22 Osaka Industrial Promotion Organization Friction stirring and working tool, and manufacturing method of friction stirred and worked product using the same
US8016179B2 (en) * 2006-07-17 2011-09-13 Wichita State University Friction stir welding tool having a scroll-free concentric region
JP2017070994A (en) * 2015-10-09 2017-04-13 株式会社Uacj Tool for friction stir welding and friction stir welding method

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
WEI L Y ET AL: "Correlation of Microstructures and Process Variables in FSW HSLA-65 Steel", WELDING JOURNAL, AMERICAN WELDING SOCIETY, MIAMI, FL, US, vol. 90, no. 5, 1 May 2011 (2011-05-01), pages 95 - S, XP001571086, ISSN: 0043-2296 *

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Publication number Publication date
GB202204254D0 (en) 2022-05-11
GB202104264D0 (en) 2021-05-12
GB2606627A (en) 2022-11-16

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